Impact sensor and control system for a longwall shearer

ABSTRACT

Methods and systems of monitoring and controlling a longwall mining system. One system includes a shearer including a cutter drum and a sensor mounted to the shearer. The system also includes an electronic controller including a processor and a memory, the electronic controller communicatively coupled to the sensor. The electronic controller is configured to receive vibration data from the sensor and determine a current vibration level associated with the shearer based on the vibration data. The electronic controller is also configured to compare the current vibration level to a vibration threshold. The electronic controller is also configured to, in response to the current vibration level exceeding the vibration threshold, adjust a cutting parameter for the cutter drum of the shearer. The electronic controller is also configured to control the cutter drum with the adjusted cutting parameter.

FIELD

Embodiments described herein relate to a longwall mining system, and,more particularly, to controlling and monitoring a longwall miningsystem based on vibration data.

BACKGROUND

Longwall mining begins with identifying a material seam to be mined and“blocking out” the seam into panels by excavating roadways around theperimeter of each panel. During excavation of the seam (for example,extraction of coal), select pillars of material may be left unexcavatedbetween adjacent panels to assist in supporting an overlying geologicalstrata. The material panels are excavated by a longwall mining system,which includes components such as automated electro-hydraulic roofsupports, a material shearing machine (i.e., a longwall shearer), and anarmored face conveyor (“AFC”) parallel to the material face. As theshearer travels the width of the material face to remove a layer or webof material, the roof supports are controlled to advance to support theroof of the newly exposed section of geological strata. The AFC is thenadvanced by the roof supports toward the material face by a distanceequal to the depth of the material layer previously removed by theshearer. Advancing the AFC toward the material face in such a mannerallows the shearer to engage with the material face and continueshearing material away from the material face.

SUMMARY

Longwall mining systems may be used to mine or extract a material ormineral, such as coal or ore. However, in some applications, a longwallmining system may encounter or be used to extract a hard material orstone. For example, the shearer may cut hard material intrusions in theseam, adjacent to the seam, or a combination thereof. Cutting a hardmaterial may result in damage to a cutter drum of the shearer, such asone or more cutting picks, cutting pick holders, and the like. When acutter drum experiences damage, the cutter drum imparts large vibrationsonto the shearer, which may result in additional damage. Thesevibrations often become worse at faster speeds. For example, instancesof large vibrations (also referred to as impact loads or events) in thelarge bearings that support the cutter drums of the shearer may lead tofailure of those bearings (for example, brinelling of the bearings), theranging arm cutter gearcase, another component of the shearer, or acombination thereof.

To solve these and other problems, embodiments described herein providemethods and systems for monitoring and controlling a longwall miningsystem based on vibration data. The embodiments described herein detectand monitor vibration data and impact events to improve reliability,operation, reporting, maintenance, and the like for the longwall miningsystem. Understanding the impacts and vibrations experienced by ashearer (for example, when an impact event occurred, where the impactevent occurred, how large the impact event was, and the like) may leadto improved reliability, operation, and maintenance of the longwallmining system. Alternatively or in addition, when remotely operating theshearer, an operator may find it difficult to accurately and efficientlyidentify when the shearer begins to cut out-of-seam. When the shearercuts out-of-seam, the shearer may begin cutting a different materialand, thus, experience a change in vibration. Accordingly, by analyzingand monitoring a vibration level experienced by the shearer, an operator(or a longwall control system) may be able to more accurately andefficiently identify when the shearer cuts out-of-seam and how to adjusta cutting parameter such that the shearer returns to cutting in seam.

Accordingly, embodiments described herein provide for, among otherthings, monitoring and controlling a longwall mining system based onvibration data by controlling a cutting parameter of a shearer,detecting an impact event, providing an impact event record of theshearer, maintaining a cutting drum within a target material seam, or acombination thereof.

For example, one embodiment provides a longwall mining system. Thesystem includes a shearer including a cutter drum and a sensor mountedto the shearer. The system also includes an electronic controllerincluding a processor and a memory, the electronic controllercommunicatively coupled to the sensor. The electronic controller isconfigured to receive vibration data from the sensor and determine acurrent vibration level associated with the shearer based on thevibration data. The electronic controller is also configured to comparethe current vibration level to a vibration threshold. The electroniccontroller is also configured to, in response to the current vibrationlevel exceeding the vibration threshold, adjust a cutting parameter forthe cutter drum of the shearer. The electronic controller is alsoconfigured to control the cutter drum with the adjusted cuttingparameter.

Another embodiment provides a method of controlling a longwall miningsystem. The method including receiving, with an electronic controller,vibration data from a sensor mounted to a shearer. The method alsoincludes determining, with the electronic controller, a currentvibration level associated with the shearer based on the vibration data.The method also includes comparing, with the electronic controller, thecurrent vibration level to a vibration threshold. The method alsoincludes in response to the current vibration level exceeding thevibration threshold, adjusting, with the electronic controller, acutting parameter for a cutter drum of the shearer. The method alsoincludes controlling, with the electronic controller, the cutter drumwith the adjusted cutting parameter.

Yet another embodiment provides a longwall mining system. The systemincludes a shearer including a cutter drum and a sensor mounted to theshearer. The system also includes an electronic controller including aprocessor and a memory, the electronic controller communicativelycoupled to the sensor. The electronic controller is configured toreceive vibration data from the sensor and determine a current vibrationlevel experienced by a cutter drum of the shearer based on the vibrationdata. The electronic controller is also configured to compare thecurrent vibration level to a vibration threshold. The electroniccontroller is also configured to detect an impact event associated withthe cutter drum of the shearer based on the comparison and generate animpact event indication associated with the impact event.

Yet another embodiment provides a method of monitoring a longwall miningsystem. The method incudes receiving, from an electronic controller,vibration data from a sensor mounted to a shearer. The method alsoincludes determining, with the electronic controller, a currentvibration level experienced by a cutter drum of the shearer based on thevibration data. The method also includes comparing, with the electroniccontroller, the current vibration level to a vibration threshold. Themethod also includes detecting, with the electronic controller, animpact event associated with the cutter drum of the shearer based on thecomparison. The method also includes generating, with the electroniccontroller, an impact event indication associated with the impact event.

Yet another embodiment provides a longwall mining system. The systemincludes a shearer including a cutter drum and a sensor mounted to theshearer. The system also includes an electronic controller including aprocessor and a memory, the electronic controller communicativelycoupled to the sensor. The electronic controller is configured toreceive an impact event indication associated with an impact event ofthe cutter drum, the impact event indication based on vibration datacollected by the sensor. The electronic controller is also configured toretrieve additional data associated with the impact event indication andlink the additional data with the vibration data of the impact eventindication. The electronic controller is also configured to create animpact event record, the impact event record including the vibrationdata and the additional data. The electronic controller is alsoconfigured to store the impact event record, and, in response toreceiving a maintenance request, export the impact event record fordisplay.

Yet another embodiment provides a method of monitoring a longwall miningsystem. The method includes receiving, with an electronic controller, animpact event indication associated with an impact event of a cutter drumof a shearer, the impact event indication based on vibration datacollected by a sensor mounted to the shearer. The method also includesretrieving, with the electronic controller, additional data associatedwith the impact event indication. The method also includes linking, withthe electronic controller, the additional data with the vibration dataof the impact event indication. The method also includes creating, withthe electronic controller, an impact event record, the impact eventrecord including the vibration data and the additional data. The methodalso includes storing, with the electronic controller, the impact eventrecord. The method also includes, in response to receiving a maintenancerequest, exporting, with the electronic controller, the impact eventrecord for display.

Yet another embodiment provides a longwall mining system. The systemincludes a shearer including a cutter drum and a sensor mounted to theshearer. The system also includes an electronic controller including aprocessor and a memory, the electronic controller communicativelycoupled to the sensor. The electronic controller is configured toreceive vibration data from the sensor and determine a current vibrationlevel experienced by the cutter drum based on the vibration data. Theelectronic controller is also configured to compare the currentvibration level to a target vibration threshold associated with a targetmaterial seam. The electronic controller is also configured to provide avisual output to an operator of the longwall mining system when thecurrent vibration level exceeds the target vibration threshold, whereinthe current vibration level exceeds the target vibration threshold whenthe cutter drum of the shearer cuts outside of the target material seam.

Yet another embodiment provides a method of monitoring a longwall miningsystem. The method includes receiving, with an electronic controller,vibration data from a sensor mounted to a shearer. The method alsoincludes determining, with the electronic controller, a currentvibration level experienced by a cutter drum of the shearer based on thevibration data. The method also includes comparing, with the electroniccontroller, the current vibration level to a target vibration thresholdassociated with a target material seam. The method also includesproviding, with the electronic controller, a visual output to anoperator of the longwall mining system when the current vibration levelexceeds the target vibration threshold, wherein the current vibrationlevel exceeds the target vibration threshold when the cutter drum of theshearer cuts outside of the target material seam.

Other aspects of the embodiments will become apparent by considerationof the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an extraction system according to some embodiments.

FIGS. 2A-2B illustrate a longwall mining system of the extraction systemof FIG. 1 according to some embodiments.

FIG. 3 illustrates collapsing of a geological strata as material isremoved from a material seam according to some embodiments.

FIG. 4 illustrates a roof support of the longwall mining system of FIGS.2A-2B according to some embodiments.

FIGS. 5A-5B illustrate a shearer of the longwall mining system of FIGS.2A-2B according to some embodiments.

FIGS. 6A-6B illustrate the shearer of FIGS. 5A-5B passing through amaterial seam according to some embodiments.

FIG. 7 illustrates an underground longwall control system according tosome embodiments.

FIG. 8 illustrates approximate locations for one or more sensors of theshearer of FIGS. 5A-5B according to some embodiments.

FIG. 9 is a flowchart of a method for controlling a longwall miningsystem using the underground longwall control system of FIG. 7 accordingto some embodiments.

FIG. 10 is a flowchart of a method for monitoring a longwall miningsystem using the underground longwall control system of FIG. 7 accordingto some embodiments.

FIG. 11 is a flowchart of another method for monitoring a longwallmining system using the underground longwall control system of FIG. 7according to some embodiments.

FIG. 12 is a flowchart of another method for monitoring a longwallmining system using the underground longwall control system of FIG. 7according to some embodiments.

FIG. 13 illustrates a visual output according to some embodiments.

DETAILED DESCRIPTION

The present application includes description of various embodimentsincluding details of construction and arrangement of components setforth in the following description and in the accompanying drawings.However, the particular constructions and arrangements of theembodiments described and shown herein are example constructions andarrangements, and the application encompasses additional constructionsand arrangements of the embodiments and additional ways of practicingand carrying out the embodiments.

Also, it is to be understood that the phraseology and terminology usedherein is for the purpose of description and should not be regarded aslimiting. The use of “including,” “comprising” or “having” andvariations thereof herein is meant to encompass the items listedthereafter and equivalents thereof as well as additional items. Theterms “mounted,” “connected” and “coupled” are used broadly andencompass both direct and indirect mounting, connecting and coupling.Further, “connected” and “coupled” are not restricted to physical ormechanical connections or couplings, and may include electricalconnections or couplings, whether direct or indirect. Also, electroniccommunications and notifications may be performed using any known meansincluding direct connections, wireless connections, etc.

A plurality of hardware and software based devices, as well as aplurality of different structural components may be utilized toimplement the embodiments described herein. In addition, embodimentsdescribed herein may include hardware, software, and electroniccomponents or modules that, for purposes of discussion, may beillustrated and described as if the majority of the components wereimplemented solely in hardware. However, one of ordinary skill in theart, and based on a reading of this detailed description, wouldrecognize that, in at least one embodiment, the electronic-based aspectsof the embodiments described herein may be implemented in software (forexample, stored on non-transitory computer-readable medium) executableby one or more processors. As such, it should be noted that a pluralityof hardware and software based devices, as well as a plurality ofdifferent structural components, may be utilized to implement theembodiments described herein. For example, “mobile device,” “computingdevice,” and “server” as described in the specification may include oneor more electronic processors, one or more memory modules includingnon-transitory computer-readable medium, one or more input/outputinterfaces, and various connections (for example, a system bus)connecting the components.

FIG. 1 illustrates an extraction system 100. The extraction system 100includes a longwall mining system 105 and a mine monitoring system 110.The extraction system 100 is configured to extract a material or product(for example, coal, ore, or another mineral) from a mine in an efficientmanner. The longwall mining system 105 physically extracts material froman underground mine. The mine monitoring system 110 monitors theoperation of the longwall mining system 105 to, for example, ensure thatthe extraction of material remains efficient, detect equipment problems,and the like. The mine monitoring system 110 may include one or morecomputer systems (e.g., personal computers, laptops, smart phones,tablets, and the like) that may be located locally at the mine, whetherunderground or above ground, one or more computer systems that may belocated remotely from the mine, or a combination thereof. The minemonitoring system 110 may communicate with the longwall mining system105 via a communication network including one or more wired and wirelessportions. The communication network may include a short range network,for example, a Bluetooth® network, a Wi-Fi network, or the like toprovide a connection between the longwall mining system 105 and the minemonitoring system 110 on a local network. In some embodiments, thelongwall mining machine communicates via a short range network tonetwork infrastructure (e.g., routers, hubs, and the like) of a longrange network or wide area network (e.g., the Internet, a cellularnetwork (e.g., 3G, long term evolution (LTE), 5G), or the like), and themine monitoring system 110 similarly has a network connection to thelong range network or wide area network. In some embodiments, the minemonitoring system 110 includes one or more cloud-based servers incommunication (e.g., via the Internet or another wide area network) withclient devices (e.g., personal computers, laptops, smart phones,tablets, and the like) of mine operator personnel located locally at themine, located remotely from the mine, or both. As noted above, longwallmining begins with identifying a material seam to be extracted, then“blocking out” the seam into material panels by excavating roadwaysaround the perimeter of each panel. During excavation of the seam (i.e.,extraction of coal), select pillars of material may be left unexcavatedbetween adjacent material panels to assist in supporting the overlyinggeological strata. The material panels are excavated by the longwallmining system 105, and the extracted material is transported to thesurface of the mine.

As illustrated in FIGS. 2A and 2B, the longwall mining system 105includes roof supports 115, a shearer 120, and an armored face conveyor(“AFC”) 125. The longwall mining system 105 is generally positionedparallel to a material face 126 (see FIG. 3). The roof supports 115 areinterconnected parallel to the material face 126 (see FIG. 3) byelectrical and hydraulic connections. Further, the roof supports 115shield the shearer 120 from overlying geological strata 127 (see FIG.3). The number of roof supports 115 used in the longwall mining system105 depends on the width of the material face 126 being mined since theroof supports 115 are intended to protect the full width of the materialface 126 from the geological strata 127. In some embodiments, the roofsupports may each have an associated number (e.g., 1 through N totalroof supports) and the roof supports may be used to identify aparticular lateral position along the material face 126 (e.g., roofsupport N/2 may be at the approximate halfway point along the materialface 126).

The shearer 120 is propagated along the line of the material face 126 bythe AFC 125, which includes a dedicated track for the shearer 120running parallel to the material face 126. The shearer track ispositioned between the material face 126 itself and the roof supports115. As the shearer 120 travels the width of the material face 126,removing a layer of material, the roof supports 115 automaticallyadvance to support the roof of the newly exposed section of thegeological strata 127.

FIG. 3 illustrates the longwall mining system 105 advancing through amaterial seam 128 as the shearer 120 removes material from the materialface 126. The material face 126 illustrated in FIG. 3 extendsperpendicular from the plane of the figure. As the longwall miningsystem 105 advances through the material seam 128 (to the right in FIG.3), the geological strata 127 is allowed to collapse behind the longwallmining system 105, forming a goaf 129. The longwall mining system 105continues to advance forward and shear more material until the end ofthe material seam 128 is reached.

While the shearer 120 travels along the side of the material face 126,extracted material falls onto a conveyor included in the AFC 125,parallel to the shearer track. The material is transported away from thematerial face 126 by the conveyor. The AFC 125 is then advanced by theroof supports 115 toward the material face 126 by a distance equal tothe depth of the material layer previously removed by the shearer 120.The advancement of the AFC 125 allows the excavated material from thenext shearer pass to fall onto the conveyor, and also allows the shearer120 to engage with the material face 126 and continue shearing materialaway. The conveyor and track of the AFC 125 are driven by AFC drives 130located at a maingate 135 and a tailgate 140, which are at distal endsof the AFC 125, as seen in FIGS. 2A-2B. The AFC drives 130 allow theconveyor to continuously transport material toward the maingate 135(left side of FIG. 2A), and allows the shearer 120 to be pulled alongthe track of the AFC 125 bi-directionally across the material face 126.

The longwall mining system 105 also includes a beam stage loader (“BSL”)145 arranged perpendicularly at the maingate end of the AFC 125. FIG. 2Billustrates a perspective view of the longwall mining system 105 and anexpanded view of the BSL 145. When the extracted material hauled by theAFC 125 reaches the maingate 135, the material is routed through a 90°turn onto the BSL 145. In some instances, the BSL 145 interfaces withthe AFC 125 at a non-right 90° angle. The BSL 145 then prepares andloads the material onto a maingate conveyor (not shown), whichtransports the material to the surface. The material is prepared to beloaded by a crusher 150, which breaks down the material to improveloading onto the maingate conveyor. Similar to the conveyor of the AFC125, the conveyor of the BSL 145 is driven by a BSL drive 155.

FIG. 4 illustrates the longwall mining system 105 as viewed along theline of the material face 126. The roof support 115 is shown shieldingthe shearer 120 from the overlying geological strata 127 by anoverhanging canopy 400 of the roof support 115. The canopy 400 isvertically displaced (i.e., moved toward and away from the geologicalstrata 127) by hydraulic legs 405, 410 (only one of which is shown inFIG. 4). The canopy 400 thereby exerts a range of upward forces on thegeological strata 127 by applying different pressures to the hydrauliclegs 405, 410. Mounted to the face end of the canopy 400 is a deflectoror sprag 415, which is shown in a face-supporting position. However, thesprag 415 may also be fully extended, as represented in phantom in FIG.4, by a sprag arm 420. An advance ram 425 attached to a base 430 allowsthe roof support 115 to be pulled toward the material face 126 as thelayers of material are sheared away.

FIGS. 5A-5B illustrate the shearer 120. The shearer 120 has an elongatedcentral control housing 500 that stores the operating controls for theshearer 120. Skid shoes 505 and trapping shoes 510 (see FIG. 5B) extendbelow the control housing 500. The skid shoes 505 support the shearer120 on the face side of the AFC 125 (i.e., the side nearest to thematerial face 126) and the trapping shoes 510 support the shearer 120 onthe goaf side of the AFC 125. Specifically, the trapping shoes 510 andhaulage sprockets engage a rack bar of the AFC 125 to allow the shearer120 to be propelled along the AFC 125 and the material face 126.Extending laterally from the control housing 500 are right and leftranging arms 515 and 520, respectively, such that the central controlhousing 500 is located between the right and left ranging arms 515 and520. The right and left ranging arms 515 and 520 are raised and loweredby hydraulic cylinders attached to the ranging arms 515, 520 and thecontrol housing 500. The hydraulic cylinders are part of a right armhydraulic system configured to articulate the right ranging arm 515 anda left arm hydraulic system configured to articulate the left rangingarm 520.

On the distal end of the right ranging arm 515 (with respect to thecontrol housing 500) is a right cutter drum 525, and on the distal endof the left ranging arm 520 is a left cutter drum 530. Each of thecutter drums 525, 530 has a plurality of mining bits 545 (for example,cutting picks) that abrade the material face 126 as the cutter drums525, 530 are rotated, thereby cutting away the material. The mining bits545 are also accompanied by spray nozzles that spray fluid during themining process in order to disperse noxious and/or combustible gasesthat develop at the excavation site, suppress dust, and enhance cooling.Each cutter drum 525, 530 is driven by an electric motor 535, 540 (forexample, a right cutter motor 535 and a left cutter motor 540) via thegear train within the ranging arms 515, 520. The right and left armhydraulic systems are configured to vertically move the right rangingarm 515 and the left ranging arm 520, respectively, which changes thevertical position of the right cutter drum 525 and the left cutter drum530, respectively.

The vertical positions of the cutter drums 525, 530 are a function ofthe angle of the ranging arms 515, 520 with respect to the controlhousing 500. Varying the angle of the ranging arms 515, 520 with respectto the control housing 500 increases or decreases the vertical positionof the cutter drums 525, 530 accordingly. For example, when the leftranging arm 520 is raised to 20° from the horizontal (i.e., 20° from alongitudinal axis 532 of the shearer 120), the left cutter drum 530 mayexperience a positive change of vertical position of, for example, 0.5m, while when the left ranging arm 520 is lowered to −20° from thehorizontal, the left cutter drum 530 may experience a negative change ofvertical position of, for example, −0.5 m. Therefore, the verticalposition of the cutter drums 525, 530 may be measured and controlledbased on the angle of the ranging arms 515, 520 with respect to thehorizontal.

The shearer 120 is displaced laterally along the material face 126 in abi-directional manner, though it is not necessary that the shearer 120cut material bi-directionally. For example, in some mining operations,the shearer 120 is capable of being pulled bi-directionally along thematerial face 126, but only shears material when traveling in onedirection. For example, the shearer 120 may be operated to cut materialover the course of a first, forward pass over the width of the materialface 126, but not cut material on its returning pass. Alternatively, theshearer 120 can be configured to cut material during both the forwardand return passes, thereby performing a bi-directional cuttingoperation. FIGS. 6A-6B illustrate the shearer 120 as it passes over thematerial face 126 from a face-end view. As shown in FIGS. 6A-6B, theleft cutter drum 530 and the right cutter drum 525 are staggered toincrease the area of the material face 126 being cut in each pass of theshearer 120. In particular, as the shearer 120 is displaced horizontallyalong the AFC 125, the left cutter drum 530 is shown shearing materialaway from the lower half (for example, a lower portion) of the materialface 126 and may be referred to as a floor cutter herein, while theright cutter drum 525 is shown shearing material away from the upperhalf (for example, an upper portion) of the material face 126. The rightcutter drum 525 may be referred to as a roof cutter herein. It should beunderstood that in some embodiments, the left cutter drum 530 cuts theupper portion of the material face 126 while the right cutter drum 525cuts the lower portion of the material face 126.

FIG. 7 illustrates an underground longwall control system 800 forcontrolling and monitoring the longwall mining system 105 according tosome embodiments. As illustrated in FIG. 7, the system 800 includes anelectronic controller 805, a right ranging arm hydraulic system 810, aleft ranging arm hydraulic system 815, a plurality of vibration sensors817 (referred to herein collectively as “the vibration sensors 817” andindividually as “the vibration sensor 817”), the right cutter motor 535,the left cutter motor 540, and other sensors 819 associated with theshearer 120. In some embodiments, the system 800 includes fewer,additional, or different components than those illustrated in FIG. 7 invarious configurations and may perform additional functionality than thefunctionality described herein. For example, in some embodiments thesystem 800 includes other components associated with the shearer 120,such as one or more actuators, motors, pumps, and the like. In someembodiments, the system 800 is located on the shearer 120. In someembodiments, the system 800 includes components not located on theshearer 120. For example, in some embodiments, the controller 805 or aportion thereof is located on another computer system in communicationwith the shearer 120. For example, at least some of the processing stepsand memory storage functions of the electronic processor 820 and thememory 825 may be performed by an electronic processor and memory on theshearer 120 and at least some of the processing steps and memory storagefunctions of the electronic processor 820 and the memory 825 may beperformed by an electronic processor and memory in communication withthe shearer 120.

In the example illustrated in FIG. 7, the controller 805 includes anelectronic processor 820 (for example, a microprocessor, an applicationspecific integrated circuit, or another suitable electronic device), amemory 825 (for example, one or more non-transitory computer-readablestorage mediums), and a communication interface 830. The electronicprocessor 820, the memory 825, and the communication interface 830communicate over one or more data connections or buses, or a combinationthereof. The controller 805 illustrated in FIG. 7 represents oneexample, and, in some embodiments, the controller 805 includes fewer,additional, or different components in different configurations thanillustrated in FIG. 7. Also, in some embodiments, the controller 805performs functionality in addition to the functionality describedherein.

The electronic processor 820 is configured to retrieve instructions fromthe memory 825 and execute instructions to perform a set of functions,including the methods described herein. For example, in someembodiments, the electronic processor 820 executes instructions forcontrolling a cutting parameter of the shearer 120, detecting an impactevent, providing an impact event record of the shearer 120, maintaininga cutter drum 525, 530 within a target material seam, or a combinationthereof. The memory 825 may include combinations of different types ofmemory, such as read-only memory (“ROM”), random access memory (“RAM”),or another non-transitory computer readable medium. As noted above, thememory 825 stores instructions executed by the electronic processor 820.The memory 825 may also store data, such as vibration data collected bythe vibration sensors 817, additional data collected by the othersensors 819, and the like. The memory 825 may also store firmware, oneor more applications, program data, filters, rules, one or more programmodules, and other executable instructions or data.

The communication interface 830 allows the controller 805 to communicatewith devices external to the controller 805 (for example, receive inputfrom and provide output to devices external to the controller 805directly or indirectly). In one example, the controller 805 communicateswith the right ranging arm hydraulic system 810, the left ranging armhydraulic system 815, one or more of the vibration sensors 817, theright cutter motor 535, the left cutter motor 540, the other sensors819, or a combination thereof through the communication interface 830.In some embodiments, the communication interface 830 includes a port forreceiving a wired connection to the right ranging arm hydraulic system810, the left ranging arm hydraulic system 815, one or more of thevibration sensors 817, the right cutter motor 535, the left cutter motor540, the other sensors 819, or a combination thereof. Alternatively orin addition, the communication interface 830 includes a transceiver forestablishing a wireless connection to the right ranging arm hydraulicsystem 810, the left ranging arm hydraulic system 815, one or more ofthe vibration sensors 600, the right cutter motor 535, the left cuttermotor 540, the other sensors 819, or a combination thereof.Alternatively or in addition, the communication interface 830communicates with a communication bus (for example, a controller areanetwork (“CAN”)) to indirectly communicate with, for example, the rightranging arm hydraulic system 810, the left ranging arm hydraulic system815, one or more of the vibration sensors 817, the right cutter motor535, the left cutter motor 540, the other sensors 819, or a combinationthereof.

The communication interface 830 also allows the controller 805 tocommunicate with the mine monitoring system 110. For example, thecommunication interface 830 further includes a port for receiving awired connection (a wired interface) or a transceiver for establishing awireless connection (a wireless interface) for communicating with themine monitoring system 110 either directly or indirectly (e.g., via oneof the aforementioned communication networks).

The vibration sensors 817 provide information regarding vibration orimpacts experienced by the shearer 120 or a component thereof, such asthe cutter drums 525, 530 or the ranging arms 515, 520. Accordingly, thevibration sensors 817 collect vibration data associated with the shearer120 or a component thereof. For example, each vibration sensor 817 maybe an accelerometer. In some embodiments, the vibration data isassociated with the shearer 120 as a whole. Alternatively or inaddition, in other embodiments, the vibration data is associated withone or more components of the shearer 120, such as the cutter drums 525,530, the ranging arms 515, 520, and the like. In such embodiments, thesystem 800 may include two or more vibration sensors 817, where eachvibration sensor 817 is associated with a particular component, system,or portion of the shearer 120. For example, a first vibration sensor 817may be associated with the right cutter drum 525 and configured tocollect vibration data associated with the right cutter drum 525, whilea second vibration sensor 817 may be associated with the left cutterdrum 530 and configured to collect vibration data associated with theleft cutter drum 530. Accordingly, in some embodiments, the vibrationdata may include multiple sets or collections of vibration data (i.e., afirst set of vibration data, a second set of vibration data, and thelike), where each set of vibration data may be associated with aparticular component, system, or portion of the shearer 120.

As illustrated in FIG. 8, the vibration sensors 817 are mounted on theshearer 120. In the exampled illustrated in FIG. 8, three vibrationsensors 817 (shown as 817A, 817B, and 817C) are mounted on the shearer120. As seen in FIG. 8, a first vibration sensor 817A is mounted in thecontrol housing 500 of the shearer 120. The first vibration sensor 817Adetects vibration data associated with or experienced by the shearer 120as a whole. In some embodiments, multiple vibration sensors 817 aremounted within the control housing 500. In such embodiments, eachvibration sensor 817 may be associated with a different component,system, or portion of the shearer 120, such as the cutter drums 525,530, the ranging arms 515, 520, and the like. Additionally, as seen inFIG. 8, a second vibration sensor 817B and a third vibration sensor 817Care mounted to the right ranging arm 515 and the left ranging arm 520,respectively. The second vibration sensor 817B detects vibration dataassociated with or experienced by the right ranging arm 515, the rightcutter drum 525, or a combination thereof. The third vibration sensor817C detects vibration data associated with or experienced by the leftranging arm 520, the left cutter drum 530, or a combination thereof.

Returning to FIG. 7, the system 800 also includes the other sensors 819.The other sensors 819 may include, for example, a left ranging arm anglesensor, a right ranging arm angle sensor, a left haulage gear sensor, aright haulage gear sensor, a pitch angle and roll angle sensor, and thelike. The other sensors 819 collect additional data associated with theshearer 120. The additional data associated with the shearer 120 mayinclude, for example, a time of day, a geographical location, anoperator characteristic or identification, an operational state, acutting parameter, a roof support position of the shearer, a positionwithin a cutting sequence, and the like. The other sensors 819 maytransmit the additional data to the controller 805 for storage in thememory 825, for data processing or analysis, and the like.

The system 800 also includes the right ranging arm hydraulic system 810,the left ranging arm hydraulic system 815, the right cutter motor 535,and the left cutter motor 540. The right ranging arm hydraulic system810 and the left ranging arm hydraulic system 815 are configured tovertically move the right ranging arm 515 and the left ranging arm 520,respectively, which changes the vertical position (i.e., a cuttingheight) of the right cutter drum 525 and the left cutter drum 530,respectively. The right cutter motor 535 and the left cutter motor 540are configured to drive the cutter drums 525, 530 via a gear trainwithin the ranging arms 515, 520. The controller 805 is configured tocontrol the right ranging arm hydraulic system 810, the left ranging armhydraulic system 815, the right cutter motor 535, and the left cuttermotor 540.

As noted above, in some embodiments, the electronic processor 820 of thecontroller 805 executes instructions for controlling the longwall miningsystem 105. For example, FIG. 9 is a flowchart of a method 900 forcontrolling the longwall mining system 105 by controlling a cuttingparameter of the shearer 120 according to some embodiments. Asillustrated in FIG. 9, the method 900 includes receiving, with theelectronic processor 820, vibration data from a sensor mounted to theshearer 120 (at block 905). As described above, the electronic processor820 may receive the vibration data from one or more of the vibrationsensors 817. In some embodiments, the electronic processor 820 mayreceive multiple sets or collections of vibration data from more thanone of the vibration sensors 817. The vibration data may include asingle vibration reading collected by the vibration sensor 817. However,in some embodiments, the vibration data may include a collection ofvibration readings collected by the vibration sensor 817. A collectionof vibration readings may refer to a plurality of vibration readingscollected by one or more of the vibration sensors 817.

The electronic processor 820 may continuously receive the vibration datain real time (or near real time) during operation of the shearer 120.Alternatively or in addition, in some embodiments, the electronicprocessor 820 receives the vibration data periodically. For example, theelectronic processor 820 may receive the vibration data based on aschedule or predetermined time period, such as every five minutes orthirty seconds. Alternatively or in addition, the electronic processormay receive the vibration data based on an operational state or statusof the shearer 120. For example, the electronic processor 820 mayreceive the vibration data after each pass along the material face 126,after advancing a predetermined distance along the material face (forexample, every two feet), after a change in operational parameters (forexample, when the operator changes a cutting speed), and the like.

After receiving the vibration data, the electronic processor 820determines a current vibration level associated with the shearer 120based on the vibration data (at block 910). The current vibration levelrepresents an amount of vibration currently being experienced by theshearer 120, one or more components of the shearer 120 (for example, theright ranging arm 515, the left ranging arm 520, the right cutter drum525, the left cutter drum 530, or the like), or a combination thereof.In some embodiments, the electronic processor 820 determines the currentvibration level based on a single vibration reading of the vibrationdata. For example, the vibration data may include an analog signal fromthe vibration sensor 817 that is proportional to the vibration sensedfrom an instantaneous vibration reading of the vibration sensor 817.However, in other embodiments, the electronic processor 820 determinesthe current vibration level based on a collection of vibration readingsof the vibration data. In such embodiments, the electronic processor 820may determine the current vibration level by determining an average, amedian, or a mean of the collection of vibration readings of thevibration data. In other words, the electronic processor 820 maydetermine the current vibration level to be the average, the median, orthe mean of the collection of vibration readings.

As seen in FIG. 9, the electronic processor 820 compares the currentvibration level to a vibration threshold (at block 915). In someembodiments, the electronic processor 820 sets or defines the vibrationthreshold based on a characteristic of a target material seam to bemined. For example, the electronic processor 820 may set the vibrationthreshold based on a vibration level of the target material seam. Thevibration level of the target material seam may represent a known orexpected vibration level associated with a material of the targetmaterial seam. Alternatively or in addition, the electronic processor820 may set or define the vibration threshold based on a characteristicof the shearer 120. For example, the electronic processor 820 may setthe vibration threshold based on a vibration limit for the shearer 120,where vibration levels exceeding the vibration limit for the shearer 120may result in damage to the shearer 120 or a component thereof. Thevibration limit for the shearer 120 may be a vibration limit for theshearer 120 as a whole or for a component thereof, such as a ranging arm515, 520 or cutter drum 525, 530. Alternatively or in addition, theelectronic processor 820 may set or define the vibration threshold basedon an operating characteristic of the shearer 120. For example, duringoperation of the shearer 120, the electronic processor 820 may adjustthe vibration threshold based on a current cutting speed of the shearer120, a current height of a ranging arm 515, 520, or a position along thematerial seam. As another example, the electronic processor 820 mayadjust the vibration threshold based on an age of the shearer 120 (forexample, lower the vibration threshold when the shearer 120 is older orincrease the vibration threshold when the shearer 120 is newer).Accordingly, in some embodiments, the electronic processor 820 may setor define the vibration threshold based on a normal or expectedvibration level for a specific shearer installation.

The electronic processor 820 compares the current vibration level to thevibration threshold in order to determine whether the current vibrationlevel exceeds the vibration threshold. As used herein, “exceeds” or“exceeding” means greater than or means greater than or equal to and“does not exceed” means less than or means less than or equal to. Whenthe current vibration level exceeds the vibration threshold, theelectronic processor 820 adjusts a cutting parameter of the shearer 120(at block 920) and controls the shearer 120 with the adjusted cuttingparameter (at block 925). The cutting parameter for the shearer 120 mayinclude, for example, a cutting speed, a cutting height, another cuttingparameter, or a combination thereof for one or more of the cutter drums525, 530. In some embodiments, in blocks 920 and 925, respectively, theelectronic processor 820 adjusts one or more cutting parameters of theshearer 120 (for example, a first cutting parameter, a second cuttingparameter, a third cutting parameter, and the like) and controls theshearer 120 with the adjusted cutting parameters. For example, theelectronic processor 820 may adjust a first cutting parameter for theleft cutter drum 530 and a second cutting parameter for the right cutterdrum 525. As another example, the electronic processor 820 may adjust afirst cutting parameter, such as a cutting speed, for the left cutterdrum 530 and a second cutting parameter, such as a cutting height, forthe left cutter drum 530. In some embodiments, the electronic processor820 continues to adjust the one or more cutting parameters until thecurrent vibration level does not exceed the vibration threshold. Inother words, the electronic processor 820 may continuously monitor thecurrent vibration level against the vibration threshold and continuouslyadjust one or more of the cutting parameters until the current vibrationlevel no longer exceeds the vibration threshold.

In some embodiments, the electronic processor 820 adjusts the cuttingparameter of the shearer 120 by adjusting a cutting speed of one or moreof the cutter drums 525, 530. The electronic processor 820 may adjust acutting speed of one or more of the cutter drums 525, 530 by reducing acutting speed or increasing a cutting speed. In such embodiments, theelectronic processor 820 may transmit a control signal to the rightcutter motor 535, the left cutter motor 540, or a combination thereof.For example, when the electronic processor 820 determines that thecurrent vibration level experienced by the right cutter drum 525 exceedsthe vibration threshold, the electronic processor 820 may transmit acontrol signal for adjusting a cutting speed to the right cutter motor535. In response to receiving the control signal, the right cutter motor535 may drive the right cutter drum 525 at an adjusted cutting speed,such as a reduced cutting speed.

Alternatively or in addition, in some embodiments, the electronicprocessor 820 adjusts the cutting parameter of the shearer 120 byadjusting a cutting height of one or more of the cutter drums 525, 530.The electronic processor 820 may adjust the cutting height of one ormore of the cutter drums 525, 530 by reducing a cutting height orincreasing a cutting height. In such embodiments, the electronicprocessor 820 may transmit a control signal to the right ranging armhydraulic system 810, the left ranging arm hydraulic system 815, or acombination thereof. For example, when the electronic processor 820determines that the current vibration level experienced by the leftcutter drum 530 exceeds the vibration threshold, the electronicprocessor 820 may transmit a control signal for adjusting a height (orposition) to the left ranging arm hydraulic system 815. In response toreceiving the control signal, the left ranging arm hydraulic system 815may control the left ranging arm 520 to adjust the cutting height of theleft cutter drum 530 such that the left cutter drum 530 cuts at, forexample, a reduced cutting height.

In some embodiments, as previously described, a vibration sensor, suchas vibration sensor 817A, is provided to sense vibration for the shearer120 as a whole, rather than to sense vibration particular to a left orright side of the shearer 120. In such embodiments, in block 920, anadjustment is made to a cutting parameter for both the right and leftcutter drums 525, 530. For example, the speed of both the right and leftcutter drums 525, 530 may be reduced; the floor cutter drum (e.g., drum525) may be raised and the ceiling cutter drum (e.g., drum 530) may belowered; or a combination thereof. In some embodiments, as previouslydescribed, vibration sensors, such as vibration sensors 817B and 817C,are provided to respectively sense vibration particular to the left andright side of the shearer 120. In such embodiments, in block 920, anadjustment is made to a cutting parameter for each side of the shearer120 on which the excessive vibration is sensed. For example, in steps905-915, when the electronic processor 820 determines that vibrationsensed by vibration sensor 817B exceeds the vibration threshold, thecutting parameter is adjusted in block 920 for the right cutter drum 525(e.g., the speed, height, or both the speed and height of the rightcutter drum 525 are adjusted). Similarly, in steps 905-915, when theelectronic processor 820 determines that vibration sensed by vibrationsensor 817C exceeds the vibration threshold, the cutting parameter isadjusted in block 920 for the left cutter drum 530 (e.g., the speed,height, or both the speed and height of the right cutter drum 530 areadjusted). Finally, in steps 905-915, when the electronic processor 820determines that vibration sensed by vibration sensor 817B and thevibration sensor 817C both exceed the vibration threshold, the cuttingparameter is adjusted in block 920 for both the right and left cutterdrums 525, 530.

In some embodiments, after controlling the cutter drum 525,530 with theadjusted cutting parameter in step 925, the electronic processor 810continues to monitor vibration of the shearer based on vibration datafrom the one or more vibration sensors 817 and continues to make furtheradjustments to the cutting parameter. For example, when furthervibration data is received, the electronic processor 810 determines acurrent vibration level based on the new vibration data and compares thecurrent vibration level to a vibration threshold. When the currentvibration level exceeds the vibration threshold (again), the electronicprocessor 810 further adjusts the cutting parameter (e.g., furtherreduces speed, further reduces height, further increases speed, orfurther increases height of one or both of the cutter drums 525,530).Additionally, in some embodiments, when the current vibration level nolonger exceeds the vibration threshold, or when the current vibrationlevel drops below a second vibration threshold that is lower than thevibration threshold previously used in step 915, the electronicprocessor 810 is configured to adjust the cutting parameter to reverse,at least in part, the previous adjustment. For example, when the initialadjustment of the cutting parameter reduced the speed of the cutterdrums 525, 530, the electronic processor 810 increases the speed of thecutter drum 525, 530 to reverse, at least in part, the previousadjustment. Similarly, when the initial adjustment of the cuttingparameter reduced the height of one of the cutter drums 525, 530, theelectronic processor 810 increases the height of the cutter drum 525,530 to reverse, at least in part, the previous adjustment.

In some embodiments, the electronic processor 820 transmits a controlinstruction to an operator of the shearer 120. The operator may beusing, for example, one or more computer devices making up the minemonitoring system 110 that is in communication with the longwall miningsystem 105, or may be using a computer device in the form of a localshearer-specific control panel in direct or indirect wired or wirelesscommunication with the longwall mining system 105. Regardless, thecomputer device, also referred to as an operator remote device, includesa user interface with an output device (for example, one or more of adisplay screen, speaker, tactile feedback device), an input device (forexample, one or more of a touchscreen, keyboard, mouse, dial,pushbuttons), or a combination therefore (e.g., a touch display). Theelectronic processor 820 may transmit the control instruction based onthe comparison of the current vibration level and the vibrationthreshold. When the current vibration level does not exceed thevibration threshold, the electronic processor 820 may transmit a controlinstruction to the operator computer device instructing the operator notto adjust a cutting parameter in order to maintain the shearer cuttingin seam. The control instruction may be displayed, audibly output, orotherwise output to the operator via the computer device. When thecurrent vibration level exceeds the vibration threshold, the electronicprocessor 820 may transmit a control instruction instructing theoperator to adjust a cutting parameter of the shearer 120 in order toreturn the shearer back to cutting in seam. For example, the controlinstruction may include an instruction to reduce a cutting speed,increase a cutting speed, reduce a cutting height, increase a cuttingheight, or a combination thereof for one or more of the cutter drums525, 530.

As noted above, the electronic processor 820 of the controller 805 mayexecute instructions for monitoring the longwall mining system 105. Forexample, FIG. 10 is a flowchart of a method 1000 for monitoring thelongwall mining system 105 by detecting an impact event according tosome embodiments. As seen in FIG. 10, the method 1000 includesreceiving, with the electronic processor 820, vibration data from asensor mounted to the shearer 120 (at block 1005), determining, with theelectronic processor 820, a current vibration level associated with theshearer 120 based on the vibration data (at block 1010), and comparing,with the electronic processor 820, the current vibration level to avibration threshold (at block 1015). With respect to method 1000, theelectronic processor 820 may perform blocks 1005-1015 in a similarmanner as described above with respect to blocks 905-915 of method 900illustrated in FIG. 9.

As illustrated in FIG. 10, the method 1000 also includes detecting, withthe electronic processor 820, an impact event associated with theshearer 120 based on the comparison (at block 1020). An impact eventoccurs when the shearer 120 (or a component thereof) experiences anabnormal load or vibration (i.e., an unusually high vibration level).The shearer 120 may experience an impact event as a result of misuse ofthe shearer 120. For example, the shearer 120 may experience an impactevent when operated outside of recommended operating parameters, such asat a cutting speed above recommended cutting speeds for the shearer 120.Alternatively or in addition, the shearer 120 may experience an impactevent as a result of difficult mining conditions, such as a hardness ofa material to be mined. Accordingly, in some embodiments, when thecurrent vibration threshold exceeds the vibration threshold, theelectronic processor 820 detects an impact event associated with theshearer 120.

In response to detecting the impact event, the electronic processor 820may generate an impact event indication associated with the impact event(at block 1025). In some embodiments, the electronic processor 820stores the impact event indication in the memory 825 of the controller805. Alternatively or in addition, the electronic processor 820transmits the impact event indication to a device external to theshearer 120, where the impact event indication may be stored, displayed,or a combination thereof. In some embodiments, the electronic processor820 generates and transmits a control instruction to an operator of theshearer 120 based on the impact event indication. The controlinstruction may include an instruction to, for example, adjust a cuttingparameter of one or more of the cutter drums 525, 530, such as reducinga cutting speed, reducing a cutting height, or the like.

Such control instructions enable an operator and other mine personnel tobe better informed regarding operation of the longwall mining system 105and to take corrective action in response to such control instructions.Without such monitoring or notifications, an operator and other minepersonnel may not be aware that the shearer 120 is encountering hardmaterial or stone, or otherwise experiencing impacts that can reduce thelifetime of the mining equipment or reduce the effectiveness of themining equipment. For example, it may be difficult for an operator toperceive or determine when vibration experienced by the longwall miningsystem 105 changes from typical vibration for which the shearer 120 isdesigned to experience to excessive vibration that could damage theshearer 120. Automated vibration sensing and impact event detection asdescribed with respect to the method 1000, however, may improve theidentification of impact events. Additionally, mine supervisors may bebetter informed to identify operators that are more likely to encountersuch impact events and provide additional training to these operators toreduce wear on the longwall mining system 105. Further advantages andbenefits are also provided by the method 1000 and not discussed herein.

FIG. 11 is a flowchart of a method 1100 for monitoring the longwallmining system 105 by providing an impact event record of the shearer 120according to some embodiments. As illustrated in FIG. 11, the method1100 includes receiving, with the electronic processor 820, an impactevent indication associated with an impact event of the shearer 120 (atblock 1105). The impact event indication may be based on vibration datacollected by one or more of the vibration sensors 817 mounted to theshearer 120. Accordingly, in some embodiments, the impact eventindication includes the vibration data used by the electronic processor820 to detect the impact event associated with the impact eventindication. In some embodiments, the electronic processor 820 generatesthe impact event indication in a similar manner as described withrespect to the method 1000 of FIG. 10.

In response to receiving the impact event indication, the electronicprocessor 820 retrieves additional data associated with the impact eventindication (at block 1110). The additional data may provide additionalinformation or detail relating to the impact event. For example, theadditional data may include a time of day when the impact eventoccurred, a geographical location of the shearer 120 when the impactevent occurred, an operator characteristic when the impact eventoccurred (for example, an operator identification), an operational stateof the shearer 120 when the impact event occurred, a cutting parameterof the shearer 120 when the impact event occurred, a position within acutting sequence when the impact event occurred, a roof support positionalong the wall at which the impact event occurred (e.g., the impactevent occurred when the cutter drum was at roof support X of the N totalroof supports 115), and the like. In some embodiments, the electronicprocessor 820 retrieves the additional data from the memory 825 of thecontroller 805. For example, the additional data may be received (by theelectronic processor 820) from one or more of the other sensors 819 andstored in the memory 825. Alternatively or in addition, the electronicprocessor 820 may retrieve the additional data from other components orsystems associated with the shearer 120.

The electronic processor 820 may link (or associate) the additional datawith the vibration data of the impact event indication (at block 1115)and create an impact event record (at block 1120). Accordingly, in someembodiments, the impact event record includes the linked vibration dataand additional data. Alternatively or in addition, in some embodiments,the impact event record includes a severity level of the impact event.After creating the impact event record (at block 1120), the electronicprocessor 820 may store the impact event record (at block 1125). Theelectronic processor 820 may store the impact event record in the memory825 of the controller 805.

In some embodiments, the electronic processor 820 stores (or adds) theimpact event record to an impact event database stored in the memory 825of the controller 805. The impact event database may include multipleimpact event records (as individual entries to the impact eventdatabase). Accordingly, in some embodiments, when the electronicprocessor 820 receives a new impact event indication, the electronicprocessor 820 creates a new impact event record (including theassociated vibration data and additional data) and adds the new impactevent record to the impact event database stored in the memory 825. Eachimpact event record may include an associated identifier (e.g., a serialnumber, alphanumeric value, date-time stamp, or other unique identifier)to enable distinguishing between records.

After storing the impact event record, the electronic processor 820 mayexport the impact event record for display (at block 1130). In someembodiments, the electronic processor 820 exports the impact eventrecord in response to receiving a request, such as a maintenancerequest. The electronic processor 820 may receive the request from adevice external to the shearer 120 (e.g., the operator remote device ora computer device of the mine monitoring system 110). In response toreceiving the impact event record, the device external to the shearer120 may display the impact event record via a display device orotherwise make the impact event record available to a user. In someembodiments, the electronic processor 820 may export a plurality ofimpact event records (e.g., the most recent impact records up to apredetermined number (e.g., 5, 10, or 25), each impact event from aparticular time period (e.g., 12 hours, 24 hours, 1 week, or 1 month))or may export each impact event record stored in the impact eventdatabase.

Such event records enable an operator and other mine personnel to bebetter informed regarding operation of the longwall mining system 105and to take corrective action in response to such control instructions.Without such monitoring or notifications, an operator and other minepersonnel may not be aware that the shearer 120 is encountering hardmaterial or stone, or otherwise experiencing impacts that can reduce thelifetime of the mining equipment or reduce the effectiveness of themining equipment. For example, it may be difficult for an operator toperceive or determine when vibration experienced by the longwall miningsystem 105 changes from typical vibration for which the shearer 120 isdesigned to experience to excessive vibration that could damage theshearer 120. Automated vibration sensing and impact event detection asdescribed with respect to the method 1000, however, may improve theidentification of impact events. Additionally, mine supervisors may bebetter informed to identify operators that are more likely to encountersuch impact events and provide additional training to these operators toreduce wear on the longwall mining system 105. Additionally, by linkingthe impact events to additional information, the event records canprovide further insight into the mine (e.g., information related to thequality or makeup of the seam), the mine operator (e.g., skill level oraggressiveness of the operator), the wear and life expectancy of theshearer 120 (e.g., whether the shearer 120 has been subject to manyimpact events and may need maintenance sooner than otherwise expected),and potential abusive operation of the shearer 120, which could berelevant for warranty determinations. Such information would otherwisebe difficult to detect, log, and analyze. Further advantages andbenefits are also provided by the method 1100 and not discussed herein.

FIG. 12 is a flowchart of a method 1200 for monitoring the longwallmining system 105 by maintaining a cutter drum 525, 530 within a targetmaterial seam according to some embodiments. As seen in FIG. 12, themethod 1200 includes receiving, with the electronic processor 820,vibration data from a sensor mounted to the shearer 120 (at block 1205),determining, with the electronic processor 820, a current vibrationlevel associated with the shearer 120 based on the vibration data (atblock 1210). With respect to method 1200, the electronic processor 820may perform blocks 1205-1210 in a similar manner as described above withrespect to blocks 905-910 of method 900 illustrated in FIG. 9.

As illustrated in FIG. 12, the method 1200 also includes comparing, withthe electronic processor 820, the current vibration level to a targetvibration threshold associated with a target material seam (at block1215). The target vibration threshold may be a known or expectedvibration level associated with a material to be mined. Accordingly, theelectronic processor 820 may set or define the target vibrationthreshold based on a known or expected vibration level associated withthe material of the target material seam to be mined by the shearer 120.

The electronic processor 820 compares the current vibration level to thetarget vibration threshold in order to determine whether the currentvibration level exceeds the target vibration threshold. When the currentvibration level exceeds the target vibration threshold, the electronicprocessor 820 provides a visual output to an operator of the longwallmining system 105 (at block 1220). The target vibration threshold isselected such that, at least in general, the current vibration levelexceeds the target vibration threshold when the shearer (i.e., thecutter drum 525, 530) cuts outside of the target material seam. In someembodiments, the electronic processor 820 provides the visual output tothe operator in real time (or near real time) during operation of thelongwall mining system 105 (i.e., the shearer 120). In such embodiments,the electronic processor 820 may transmit (or provide) the visual outputto a device external to the shearer 120, such as the operator remotedevice used by an operator to control the longwall mining system 105(i.e., the shearer 120). The visual output may be displayed to theoperator via a display device of the remote device.

Accordingly, in some embodiments, the visual output provides a graphicalrepresentation of the current vibration level in relation to the targetvibration threshold. For example, FIG. 13 illustrates an exemplaryvisual output 1300 according to some embodiments. In the exampleillustrated in FIG. 13, the visual output 1300 provides a graphicalrepresentation of the current vibration level in relation to the targetvibration threshold in bar graph form. The visual output 1300 indicatesa current vibration level of the right cutter drum 525 and a currentvibration level of the left cutter drum 530. As illustrated in FIG. 13,the current vibration level for the right cutter drum 525 and the leftcutter drum 530 are visually depicted by a first bar 1305 and a secondbar 1310, respectively, where the height of the first bar 1305 and thesecond bar 1310 represents the current vibration level of the rightcutter drum 525 and the left cutter drum 530, respectively.Alternatively or in addition, the current vibration level for the rightcutter drum 525 and the left cutter drum 530 may be depicted by acurrent vibration level indication, such as a numerical value,associated with the first bar 1305 and the second bar 1310,respectively. For example, as illustrated in FIG. 13, the currentvibration level experienced by the right cutter drum 525 may bepositioned within the first bar 1305 of the visual output 1300(represented in FIG. 13 as “Vib_Right”). Similarly, the currentvibration level experienced by the left cutter drum 530 may bepositioned within the second bar 1310 of the visual output 1300(represented in FIG. 13 as “Vib_Left”).

The visual output 1300 also provides a visual indication of thevibration threshold (or the target vibration threshold). For example, asillustrated in FIG. 13, the vibration threshold is depicted as a dashedline 1315. Alternatively or in addition, the visual output 1300 mayinclude the vibration threshold as a numerical value. For example, asillustrated in FIG. 13, the visual output 1300 includes the vibrationthreshold as a numerical value (represented in FIG. 13 as “Vib_Thresh”)associated with the dashed line 1315.

In some embodiments, the visual output 1300 indicates a differencebetween the current vibration level and the vibration threshold. Forexample, as illustrated in FIG. 13, the visual output 1300 includes afirst difference indication 1320 for the right cutter drum 525(represented in FIG. 13 as “Diff_Right”) and a second differenceindication 1325 for the left cutter drum 530 (represented in FIG. 13 as“Diff_Left”). As seen in FIG. 13, the first difference indication 1320indicates that the difference between the current vibration level of theright cutter drum 525 and the vibration threshold is Diff_Right.Accordingly, the first difference indication 1320 indicates that thecurrent vibration level experienced by the right cutter drum 525 exceedsthe vibration threshold by Diff_Right. As also seen in FIG. 13, thesecond difference indication 1325 indicates that the difference betweenthe current vibration level of the left cutter drum 530 and thevibration threshold is Diff_Left. Accordingly, the second differenceindication 1325 indicates that the current vibration level experiencedby the left cutter drum 530 is below the vibration threshold byDiff_Left.

In some embodiments, the visual output 1300 indicates whether acomponent of the shearer 120 is cutting in-seam, cutting out-of-seam,approaching the seam, or a combination thereof by modifying acharacteristic of the visual output 1300, such as a color or ananimation. For example, the first bar 1305 may be a first color (forexample, red) to indicate that the right cutter drum 525 is cuttingout-of-seam, while the second bar 1310 may be a second color (forexample, green) to indicate that the left cutter drum 530 is cutting inseam. However, when the current vibration level experienced by the leftcutter drum 530 approaches the vibration threshold, the second bar 1310may change to a third color (for example, yellow) to indicate that theleft cutter drum 530 is approaching the seam. As another example, thefirst bar 1305 may perform an animation, such as a flash or pulse, toindicate that the right cutter drum 525 is cutting out-of-seam.

The visual output 1300 may indicate that one or more of the cutter drums525, 530 (or another component of the shearer 120) is cutting outside ofthe target material seam (i.e., is cutting out-of-seam). For example, asillustrated in FIG. 13, the visual output 1300 includes a warningindication 1350 indicating that the right cutter drum 525 is cuttingout-of-seam. In some embodiments, the visual output 1300 includes aninstruction for adjusting one or more of the cutting parameters of thecutter drum 525, 530 for cutting within the target material seam. Inother words, the visual output 1300 instruct an operator regarding howto return the shearer 120 to cutting in seam. For example, the visualoutput 1300 may include an instruction to reduce or increase a cuttingspeed of the cutter drum 525, 530, reduce or increase a cutting heightof the cutter drum, or a combination thereof. As seen in FIG. 13, thevisual output 1300 includes an instruction 1355 to reduce a cuttingheight of the right cutter drum 525. In some embodiments, theinstruction included in the visual output 1300 may include a specificcutting parameter value for controlling the shearer 120, such as asuggested cutting speed value or a suggested cutting height value.

Alternatively or in addition, in some embodiments, the electronicprocessor 820 provides an additional visual output to the operator ofthe longwall mining system 105 when the current vibration level does notexceed the target vibration threshold. The current vibration level doesnot exceed the target vibration threshold when the cutter drum 525, 530of the shearer 120 cuts within the target material seam. In suchembodiments, the additional visual output indicates that the shearer 120(i.e., the cutter drum 525, 530) cuts within the target material seam.In some embodiments, the additional visual output is included within thevisual output 1300. For example, as illustrated in FIG. 13, the visualoutput 1300 includes an additional visual output 1370. As seen in FIG.13, the additional visual output 1370 indicates that the left cutterdrum 530 is cutting in seam.

The various methods described above are described as including one ormore functions performed by the electronic processor 810. Thesefunctions may also be described as being carried out by the electroniccontroller 805, which includes the electronic processor 810 and thememory 825, among other components.

Thus, embodiments described herein provide, among other things, systemsand methods for controlling and monitoring a longwall mining systembased on vibration data. Various features and advantages of theembodiments described herein are set forth in the following claims.

1. A longwall mining system, the system comprising: a shearer includinga cutter drum; a sensor mounted to the shearer; and an electroniccontroller including a processor and a memory, the electronic controllercommunicatively coupled to the sensor, and the electronic controllerconfigured to receive vibration data from the sensor, determine acurrent vibration level associated with the shearer based on thevibration data, compare the current vibration level to a vibrationthreshold, wherein the vibration threshold is set based on acharacteristic of the shearer, in response to the current vibrationlevel exceeding the vibration threshold, adjust a cutting parameter forthe cutter drum of the shearer, control the cutter drum with theadjusted cutting parameter; and transmit a control instruction to anoperator of the longwall mining system; wherein the control instructionincludes an instruction to at least one selected from a group consistingof reduce a cutting speed of the cutter drum and adjust a cutting heightof the cutter drum.
 2. The system of claim 1, wherein the sensor ismounted to a ranging arm of the cutter drum.
 3. The system of claim 1,wherein the sensor is mounted within a control housing of the shearerlocated between a right ranging arm and a left ranging arm of theshearer.
 4. (canceled)
 5. The system of claim 1, wherein the cuttingparameter includes at least one selected from a group consisting of acutting speed of the cutter drum and a cutting height of the cutterdrum.
 6. The system of claim 1, wherein the electronic controller isconfigured to adjust the cutting parameter by reducing a cutting speedof the cutter drum.
 7. The system of claim 1, wherein the electroniccontroller is configured to adjust the cutting parameter by adjusting acutting height of the cutter drum.
 8. The system of claim 1, wherein thesensor is a first vibration sensor mounted to a left ranging arm of theshearer, and the cutting drum is a left cutting drum of the shearer, andthe system further comprises: a right cutting drum of a right rangingarm of the shearer; and a second vibration sensor mounted to the rightranging arm of the shearer, wherein the electronic controller is furtherconfigured to: receive second vibration data from the second vibrationsensor, determine a second current vibration level associated with theshearer based on the second vibration data, compare the second currentvibration level to the vibration threshold, in response to the secondcurrent vibration level exceeding the vibration threshold, adjust asecond cutting parameter for the right cutter drum of the shearer, andcontrol the right cutter drum with the second adjusted cuttingparameter. 9-10. (canceled)
 11. A method of controlling a longwallmining system, the method comprising: receiving, with an electroniccontroller, vibration data from a sensor mounted to a shearer;determining, with the electronic controller, a current vibration levelassociated with the shearer based on the vibration data; setting thevibration threshold based on a characteristic of the shearer; comparing,with the electronic controller, the current vibration level to avibration threshold; in response to the current vibration levelexceeding the vibration threshold, adjusting, with the electroniccontroller, a cutting parameter for a cutter drum of the shearer; andcontrolling, with the electronic controller, the cutter drum with theadjusted cutting parameter; and outputting a control instruction to anoperator of the longwall mining system; wherein the control instructionincludes maintaining the cutter drum within a target material seam. 12.(canceled)
 13. The method of claim 11, wherein receiving the vibrationdata from the sensor includes receiving the vibration data from a sensormounted within a control housing of the shearer, the control housing ofthe shearer located between a right ranging arm and a left ranging armof the shearer.
 14. The method of claim 11, wherein setting thevibration threshold includes setting the vibration threshold based on acharacteristic of a target material seam to be mined by the shearer andthe characteristic of the shearer.
 15. The method of claim 11, whereinadjusting the cutting parameter includes adjusting a cutting speed ofthe cutter drum.
 16. The method of claim 11, wherein adjusting thecutting parameter includes adjusting a cutting height of the cutterdrum.
 17. The method of claim 11, wherein the sensor is a firstvibration sensor mounted to a left ranging arm of the shearer, and thecutting drum is a left cutter drum of the shearer, and the methodfurther comprises: receiving second vibration data from a secondvibration sensor mounted on a right ranging arm of the shearer, theright ranging arm including a right cutter drum; determining a secondcurrent vibration level associated with the shearer based on the secondvibration data; comparing the second current vibration level to thevibration threshold; in response to the second current vibration levelexceeding the vibration threshold, adjusting a second cutting parameterfor the right cutter drum of the shearer; and controlling the rightcutter drum with the second adjusted cutting parameter.
 18. The methodof claim 11, wherein the control instruction includes at least oneselected from a group consisting of reduce a cutting speed of the cutterdrum and adjust a cutting height of the cutter drum.
 19. The method ofclaim 11, wherein adjusting the cutting parameter includes adjusting thecutting parameter until the current vibration level does not exceed thevibration threshold.
 20. The system of claim 1, wherein the control ofthe cutter drum with the adjusted cutting parameter maintains the cutterdrum within a target material seam.
 21. (canceled)
 22. The system ofclaim 1, wherein the characteristic of the shearer includes at least oneselected from a group consisting of a vibration limit of the shearer, anoperating characteristic of the shearer, an age of the shearer, and anexpected vibration level for an installation of the shearer.
 23. Thesystem of claim 1, wherein the electronic processor is configured toreceive the vibration data in response to a change in an operationalstate of the shearer.
 24. A longwall mining system, the systemcomprising: a shearer including a cutter drum; a sensor mounted to theshearer; and an electronic controller including a processor and amemory, the electronic controller communicatively coupled to the sensor,and the electronic controller configured to receive vibration data fromthe sensor, determine a current vibration level associated with theshearer based on the vibration data, compare the current vibration levelto a vibration threshold, wherein the vibration threshold is set basedon a characteristic of the shearer, in response to the current vibrationlevel exceeding the vibration threshold, adjust a cutting parameter forthe cutter drum of the shearer, and control the cutter drum with theadjusted cutting parameter; wherein the characteristic of the shearerincludes at least one selected from a group consisting of a vibrationlimit of the shearer, an age of the shearer, and an expected vibrationlevel for an installation of the shearer.